Adaptive multi-process additive manufacturing systems and methods

ABSTRACT

Apparatuses and methods are provided that provide adaptive multi-process additive manufacturing systems for monitoring, measuring, and controlling additive manufacturing processes. A first laser (e.g., a fiber laser) is used for melting and consolidating the powder, and a second laser is utilized for dual purpose: (a) for metrology to measure the surface roughness, dimensional accuracy, material properties, etc., and (b) based on the evaluated measurements to take corrective actions (laser ablation, etc.) to attain the desired surface finish and dimensional accuracy. Various elements provide defect detection, defect identification, and defect response actions which remove defect related material or address under print or missing material in a build object.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/649,647, filed Mar. 29, 2018, entitled “AdaptiveMulti-Process Additive Manufacturing System”, the disclosure of which isexpressly incorporated by reference herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

The invention described herein was made in the performance of officialduties by employees of the Department of the Navy and may bemanufactured, used and licensed by or for the United States Governmentfor any governmental purpose without payment of any royalties thereon.This invention (Navy Case 200,502 and 200,437) is assigned to the UnitedStates Government and is available for licensing for commercialpurposes. Licensing and technical inquiries may be directed to theTechnology Transfer Office, Naval Surface Warfare Center CoronaDivision, email: CRNA_CTO@navy.mil.

FIELD OF THE INVENTION

The invention relates to adaptive multi-process additive manufacturing(AM) systems for monitoring, measuring, and controlling AM processes. Inparticular, various embodiments focus on in-situ and real-timemonitoring and feedback which is used to identify defects and correctthem after or as layers are being built-up by an AM system. Correctivestrategies are selected by an embodiment of the system based ondetection or measurement systems or alternatively allows a newcorrective strategy to be input.

BACKGROUND AND SUMMARY OF THE INVENTION

Embodiments of this disclosure relates to systems and methods ofperforming real-time in-situ process monitoring, measurement, andcontrol of additive manufacturing (AM) processes in order to achieve thedesired surface finish and dimensional accuracy.

Real-time, in-situ process monitoring and control can play a significantrole in achieving improved surface finish and dimensional accuracy.Various high-end non-destructive testing (NDT) and metrology methodssuch as coordinate measuring machine (CMM), X-ray computer tomography(X-ray CT), laser ultrasonic testing, and optical methods (pyrometers,IR and CMOS cameras, profilometer, etc.) can be used for post-processingof AM printed parts to identify defects (external or internal), surfacefinish, and dimensional accuracy. However, all these methods areexpensive, time-consuming, and data-intensive that need significantpost-processing analyses to produce required information and enablecorrective or responsive action to a wide variety of defects ormanufacturing failures. High precision application such as aviation ormission close tolerance applications are particularly impacted by thesecapability gaps. Therefore, none of these methods are currently capableto carry out the much needed real-time, in-situ process monitoring,measurement, and control. Because of these limitations, AM parts showthe distinct surface roughness (like staircase) with poor dimensionalaccuracy, along with various internal structural and micro-structuraldefects that seriously hampers the wide spread adoption of AMtechnology. Generally, the post-processing methods (subtractivemachining) such as grinding, polishing, sand blasting, milling, etc. areutilized to attain the desired surface finish and dimensional accuracythat are needed to certify a part. However, these processes are timeconsuming and need material handling.

Embodiments of the invention provide an advantage of completely/partlyremoving or eliminating post-processing (subtractive machining) stepsand using another laser (ultrafast) for corrective action to achievedesired surface roughness and dimensional accuracy. Embodiments of theinvention can utilize a hybrid approach where two lasers originatingfrom the same or different laser sources are used. A first laser (e.g.,a fiber laser) is used for melting and consolidating the powder, and asecond laser is utilized for dual purpose: (a) for metrology to measurethe surface roughness, dimensional accuracy, material properties, etc.,and (b) based on the evaluated measurements to take corrective actions(laser ablation, etc.) to attain the desired surface finish anddimensional accuracy. These embodiments enable quality improvementthrough real-time in-situ process monitoring, measurement, and controlcan oversee the process closely and allow control on processingparameters, enhance repeatability and interchangeability of parts,create appreciable time savings through multi-operation stage withhigh-end features, no post-processing machining requirements, and nomaterial handling, and allow ready-to-use printed parts. Embodiments cancompletely/partly eliminate post-processing (subtractive machining)steps and use another laser (ultrafast) for corrective action to achievethe desired surface roughness and dimensional accuracy.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1A shows a simplified diagram of a high level system overview of anembodiment of the invention;

FIG. 1B shows another simplified system architecture of one embodimentof the invention;

FIG. 2 shows an exemplary high level or simplified AM manufacturingprocess with in-situ process monitoring and feedback control loops suchas those shown in FIG. 3;

FIG. 3 shows an exemplary real-time, in-situ process monitoring andfeedback control loop system;

FIG. 4 shows exemplary corrective actions including strategies toaddress underprint and overprint defects;

FIG. 5 shows a simplified software module architecture in accordancewith one exemplary embodiment of the invention;

FIG. 6A shows an exemplary method in accordance with one exemplaryembodiment of the invention;

FIG. 6B shows a continuation of the FIG. 6A exemplary method inaccordance with one exemplary embodiment of the invention; and

FIG. 6C shows a continuation of the exemplary FIGS. 6A and 6B exemplarymethod in accordance with one exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to precise forms disclosed. Rather,the embodiments selected for description have been chosen to enable oneskilled in the art to practice the invention.

Generally, embodiment of the invention includes exemplary AM systemsutilizing, for example, a powder bed fusion process. A first laser(e.g., a fiber laser) is used for melting and consolidating the powder,and a second laser is utilized for dual purpose: (a) for metrology tomeasure the surface roughness, dimensional accuracy, materialproperties, etc., and (b) based on the evaluated measurements to takecorrective actions (laser ablation, etc.) to attain the desired surfacefinish and dimensional accuracy. Another exemplary AM system can beprovided utilizing a directed energy deposition process. A first laser(e.g., a fiber laser) can be used for melting and consolidating thepowder, and a second laser is utilized for dual purpose: (a) formetrology to measure the surface roughness, dimensional accuracy,material properties, etc., and (b) based on the evaluated measurementsto take corrective actions (laser ablation, etc.) to attain the desiredsurface finish and dimensional accuracy. Exemplary embodiments caninclude computer-controlled fully automated Robotic arm with six-axismotion capability, which can accommodate multiple lasers. A first lasercan be used for additive manufacturing, and a second laser can be usedfor corrective action (e.g., additive and subtractive manufacturing).Exemplary embodiments can accommodate optical tools and laser scan headsand manage multiple processes. Various types of laser can be used,including fiber lasers, Nd:YAG lasers, ultrafast lasers, etc. A full orpartial enclosure can surround the AM site to provide a controlledenvironment. Exemplary embodiments can use a computer-controlled fullyautomated Gantry Robot with 6-axis motion capability, which canaccommodate multiple lasers. A first laser can be used for additivemanufacturing, and a second laser can be used for corrective action(e.g., additive and subtractive manufacturing). Exemplary embodimentscan accommodate optical tools and laser scan heads and manage multipleprocesses. Various types of laser can be used, including fiber lasers,Nd:YAG lasers, ultrafast lasers, etc. A full or partial enclosure cansurround the AM site to provide a controlled environment. Alternativeembodiments can include other laser-based processing such as: lasermachining (e.g., drilling, cutting, milling, etc.), laser polishing,laser surface texturing, laser surface engineering, and laser surfacecoating.

FIG. 1A shows a simplified system architecture of one embodiment of theinvention. In particular, a 3D model input file 11 which has beencreated via 3D printing file and 3D model design analysis systems iscreated. The 3D model input file 11 is input into an AM system printersystem 11 which includes a display, computer hub, an optional cloudstorage system, a data storage hard drive, and a database system whichinteract with each other. A real time, in-situ monitoring and feedbackcontrol loop (ISM FCL) system 15 is provided which communicates andoperates a Corrective Strategies Section 17 and a Build Feedback andMachine Learning Platform 21. The Corrective Strategies Section 17includes machine instructions for altering operation of the AM 3Dprinter system 13 in response to detected defects which include OverPrint and Under Print defects. The Build Feedback and Machine LearningPlatform 21 system includes a Defect Exploration System 23, a DefectIdentification System 25 and an Add New Defect Type and Definition in asystem database 27. The ISM FLC System 15 operates the DefectExploration System which receives sensor inputs (See FIG. 1A forexample) and compares stored data or 3D Model Input File data 21 withthe received sensor inputs to determine if a defect then identifies aspecific type of defect via the Defect Identification system 25. TheDefect Identification system 25 data is then correlated by the ISM FCL15 system with Corrective Strategies machine instructions and database17 associated with the identified specific type of defect; then storedinstructions for operating a laser (e.g., see FIG. 1A) to ablate anoverprint or add additional additive manufacturing material to an underprint condition or defect (or another type of defect). Note varioussoftware systems, e.g., ISM FLC 15, Defect Identification System 25,Corrective Strategies System, etc, can be hosted on the computer that isincluded in the AM system 13 or on another system in communication withthe computer coupled with the 3D printer AM system 13. Multiple laserscan be used to increase effectiveness or precision of removal effectswhere the lasers can be oriented in a variety of ways to reduce damageto adjacent sections of a build layer with an overprint or another typeof defect (e.g., texture, etc).

FIG. 1B shows another simplified system architecture of one embodimentof the invention. In particular, A machine learning stack 31 can beprovided which implements or hosts, e.g., the FIG. 1A Build Feedback andMachine Learning Platform 21 (or the Platform 21 can be hosted on thelocal computer 39. The machine learning stack 31 can include aPredictive Analytic Section, a Descriptive Analytics Section, and aPrescriptive Analytics Section which collectively communicate with acloud based system with a big data environment (optional) and a LocalComputer 13 hosting a Real Time Feedback Loop Control System (FLCSystem) 15 (e.g., the FIG. 1A ISM FLC System 15 hosted on computer 13).The Local Computer in this embodiment also hosts the FIG. 1A BuildFeedback and Machine Learning Platform (BFMLP) 21 system that includesthe Defect Exploration System 23, Defect Identification System 25 andAdd New Defect Type and Definition in a system database 27 machineprocessing or instruction sections. The FLC System 15, BFMLP 21, andCorrective Strategies machine instructions and database 17 collectivelyoperate to operate the multiple lasers 41 (with orientation orpositioning systems (not shown)) and the AM System 13 to perform realtime defect detection and correction. A variety of sensors areintegrated into the system including temperature sensors, 3D profilemeasurement sensors, and melt pool temperature sensors which providedata inputs to various elements of the overall exemplary system. A buildplate is shown as a part of the AM System 13.

FIG. 2 shows an exemplary high level or simplified AM manufacturingprocess with in-situ process monitoring and feedback control loopsoperated by system components as those shown in FIGS. 1A, 1B, and 3. The3D Model Input File 11 is input into the AM System or 3D Printer 13which performs layer by layer printing processing (layer 1, layer 2,layer 3, layer N, etc) while the Real Time, In-Situ Process Monitoringand Feedback Control Loop System (E.g., see FIG. 1A, 1B, and FIG. 3; FLCSystem 15, BFMLP 21, and Corrective Strategies machine instructions anddatabase 17) perform detect identification and correction to each layer.

FIG. 3 shows an exemplary real-time, in-situ process monitoring andfeedback control loop system with more detail regarding the BFMLP 21system. In particular, BFMLP 21 system includes the Defect ExplorationSystem 23, Defect Identification System 25 and Add New Defect Type andDefinition in a system database 27 machine processing or instructionsections. The Defect Exploration System 23 controls sensors (e.g., imagecapture sensors that capture photographic, video graphics, optical,scanning electron microscope (SEM), tunneling electron microscope (TEM)systems as well as thermal profile capture sensors, and sensors thatcapture or detect distortion or dimensional profile data. The DefectIdentification System 25 includes image or sensor data recognitionsystems (e.g., feature recognition). Embodiments also can performcomparison of captured thermal profile sensor data with a database ofstored defect data or comparator data. The Defect Identification 25 alsocan perform inspection or comparison of captured distortion/dimensions(x, y, z) sensor data outputs with data base of defects. The Add NewDefect Type and Definition system 27 further operates to take image orsensor data, thermal profile data, and/or inspection ofdistortion/dimensional profile data to a data storage system 29 (oranother database in an alternative embodiment). Defect exploration,identification and optically add defect operations can be repeated foreach layer as they are produced by the AM/3D printer system 13.

FIG. 4 shows exemplary corrective actions including strategies toaddress underprint and overprint defects; For example, an Over Printcorrective action can include machine instructions which orient one ormore lasers to execute a laser ablation operation on an over print orother defect condition on an AM build layer. An exemplary ablation lasercan be mounted on a 7 axis system to provide precise orientations of thelaser based on a stored library of machine instructions which selectmaneuvering of the laser(s) and operation of the laser to include power,pulse type, selection of laser type (e.g., ultrashort pulse laser, etc).The Corrective Actions 17 section further includes a library ofcorrective actions or machine instructions associated with various typesof under print related defects where machine instructions operate the AMsystem 13 to perform AM deposition. Alternative embodiments can includea system which applies AM build material directly to an defect location,e.g., under print location, independently of the AM System 13 thenoperates a separate AM laser to perform layer touch up or spot build upon a particular defect location. Corrective actions are selected andexecuted (operation of various elements of the system) for every layeras defects are detected until end of AM printing operations. Removal ofmaterials ablate material for dimensional accuracy, address distortionsand other types of over prints. Add material operations fill voids,inclusions, reduce or eliminate dimensional inaccuracy, underprintedfeatures, apply added material etc to mitigate this class of defects.

FIG. 5 shows a simplified software module architecture in accordancewith one exemplary embodiment of the invention. In particular, systemsoftware modules are provided which include: Defect explorationprocessing section 303 including sensor data with defect or featuredetection/comparison to build model geometry or shape to ID AM builddefects (Neural network/machine learning/modeling system),distortion/dimensional profile comparator with model or CAD file data.Defect identification processing section 305 including processingsequences for identification of specific defects based on comparison ofdefect exploration sensor outputs with defect library file data. Defectresponse control processing section 307 including sequences whichcorrelate defect identification data from the defect identificationprocessing section with defect response machine instructions from aplurality of defect responses that correct a build layer to include afirst and second response; machine processing instructions then executethe first response including orienting laser using an automated armatureor movable fixture, selection of laser power and modulation, operatelaser, and image capture and comparison with desired structure tomonitor defect ablation or correction until defect is removed ormitigated, the sequences further include ones that execute the secondresponse including adjusting a second layer to adjust for actual buildafter defect ablation or correction is completed.

FIG. 6A shows an exemplary method in accordance with one exemplaryembodiment of the invention. At Step 401: Providing an additivemanufacturing (AM) system including an in-situ measurement andcorrective action system including: an AM system that produces aplurality of AM build layers based on an input AM build file; aplurality of lasers that are operable to selectively orient on andablate material from one or more of the AM build layers and measure theplurality of AM build layers during and after the have been produced bythe AM system; an orienting system for the plurality of lasers; asensing system that includes a sensor or imager system that selectivelyorients towards and generates sensor outputs or sensor data capturese.g., image captures of each AM build layer during or after printing,the sensor outputs or sensor data captures include electromagnetic(e.g., optical, x-rays, etc) and/or thermal images, the sensing systemfurther can include one or more of a group comprising a scanningelectron microscope (SEM), a transmission electron microscope (TEM),thermal profile, and distortion/dimensional profile sensing systems; ameasuring system that receives inputs from at least one of the pluralityof lasers and measures the AM build layer during and after the AM systemprints or produced the AM build layers; a data storage or hard drivestoring a plurality of in-situ monitoring and corrective action systemmachine instructions to operate the system comprising: a defectexploration system that operates the sensing system to generate thesensor outputs or sensor data capture of said AM build layers; a defectidentification system that classifies or identifies one or more defectsin the AM build layers that correlate elements of the sensor outputs orsensor data with stored defect data, the defect identification systemaccesses a defect library including a plurality of detectable buildlayer defect patterns including comparison of the sensor system anddefect exploration system outputs with entries in the defect libraryfiles, e.g. by a feature or pattern recognition system, to identify arespective one of the one or more defects, wherein the defect libraryincludes pixel patterns associated with one or more defects which arecompared by the feature recognition system, wherein the defectidentification system comprises a feature or pattern recognition systemwhich receives outputs of the sensing system including images of thebuild layers from a build object produced from the AM system, thefeature or pattern recognition system comprises a neural network and/orother machine learning system; (Continued at FIG. 6B)

FIG. 6B shows a continuation of the FIG. 6A exemplary method inaccordance with one exemplary embodiment of the invention. Step 401(continued): a corrective action section that includes a correctiveaction library that includes a plurality of build layer defectcorrective action processing sequences that control the AM system or atleast one of the plurality of lasers, wherein the corrective actionsection or the in-situ monitoring system further includes machineinstructions that selects one or more of the build layer defectcorrection action processing sequences in the corrective action librarybased on correlation between a detectable build layer defect pattern orpatterns and an associated build layer defect correction actionprocessing sequences stored in the corrective action library, whereineach of the build layer defect correction action processing sequencesinclude predetermined corrective response actions associated with eachof the defect library entries including an overprint and under printcorrective response action, wherein the plurality of build layer defectcorrection action processing sequences includes machine instructionsequences for controlling at least one of the plurality of lasers toablate some or all of a detected said build layer defects and machineinstruction sequences for controlling the AM printer to fill in oradjust a geometry or section of a subsequently applied build layeradjacent to respective detected defects; a defect library and correctiveaction library input section that provides an operator of the in-situmeasurement and corrective action system a user interface to acceptoperator inputs of new said plurality of build layer defect correctiveaction processing sequences and new said plurality of detectable buildlayer defect patterns; an in-situ monitoring system section thatreceives inputs from the feature recognition system and interacts orcontrols the defect exploration system, the defect identificationsystem, and the corrective action section as well as the AM system; andat least one controller system that includes at least one processorwhich executes the machine instructions for controlling various elementsincluding the AM system, the plurality of lasers, the measuring system,the in-situ monitoring and corrective response action system, and theorienting system; Step 303: Operating the AM system to generate an AMbuild layer on a build platform or section; Step 305: Identifying saidone or more defects using the in-situ measurement correction actionsections, the measurement system, the sensor system, the in-situmonitoring section, the defect exploration system, the defectidentification system, and corrective response action system, and thecontroller system executing the machine instructions to identify the oneor more defects in the build layer after some or all of the build layerproduced; (continued at FIG. 6C)

FIG. 6C shows a continuation of the exemplary FIGS. 6A and 6B exemplarymethod in accordance with one exemplary embodiment of the invention.Continued from FIG. 6B: Step 307: Selecting one of the corrective actionusing the in-situ monitoring section, the defect exploration section,the defect identification section, and corrective response actionsection, that includes one or more said build layer defect correctionactions including one or more layer adjustment actions or one or morelayer section ablative actions, wherein the one or more layer adjustmentaction comprises controlling the AM printer, to adjust the AM system tobuild the subsequently applied or next AM product layer to adjust ashape or geometry of the subsequently applied or next AM build layer inresponse to the detected one or more defects in a previously applied orbuilt layer comprising reducing width or adding width at or in proximityto the detected defect, wherein the one or more layer section ablativeactions comprises selecting an ablative or material removal operationsequence stored within the corrective action library, wherein theablative or material removal operation includes operating at least oneof the plurality of lasers and orienting system to remove some or all ofthe identified defect while operating another laser of said plurality oflasers to monitor ablation or removal of the identified defect apredetermined time period and at a predetermined power defined by the anablative or material removal operation sequence until the in-situmonitoring system determines the defect, including a structuralirregularity, is removed or partially removed from the AM build layer.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

1. An additive manufacturing (AM) system including an in-situmeasurement and corrective action system comprising: an AM system thatproduces a plurality of AM build layers based on an input AM build file;a plurality of lasers that are operable to selectively orient on andablate material from one or more of the AM build layers and measure theplurality of AM build layers during and after the have been produced bythe AM system; an orienting system for the plurality of lasers; asensing system that includes a sensor or imager system that selectivelyorients towards and generates sensor outputs or sensor data capturese.g., image captures of each AM build layer during or after printing,the sensor outputs or sensor data captures include electromagnetic(e.g., optical, x-rays, etc) and/or thermal images, the sensing systemfurther can include one or more of a group comprising a scanningelectron microscope (SEM), a transmission electron microscope (TEM),thermal profile, and distortion/dimensional profile sensing systems; ameasuring system that receives inputs from at least one of the pluralityof lasers and measures the AM build layer during and after the AM systemprints or produced the AM build layers; a data storage or hard drivestoring a plurality of in-situ monitoring and corrective action systemmachine instructions to operate the system comprising: a defectexploration system that operates the sensing system to generate thesensor outputs or sensor data capture of said AM build layers; a defectidentification system that classifies or identifies one or more defectsin the AM build layers that correlate elements of the sensor outputs orsensor data with stored defect data, the defect identification systemaccesses a defect library including a plurality of detectable buildlayer defect patterns including comparison of the sensor system anddefect exploration system outputs with entries in the defect libraryfiles by a feature or pattern recognition system to identify arespective one of the one or more defects, wherein the defect libraryincludes pixel patterns associated with one or more defects which arecompared by the feature recognition system, wherein the defectidentification system comprises a feature or pattern recognition systemwhich receives outputs of the sensing system including images of thebuild layers from a build object produced from the AM system, thefeature or pattern recognition system comprises a neural network and/orother machine learning system; a corrective action section that includesa corrective action library that includes a plurality of build layerdefect corrective action processing sequences that control the AM systemor at least one of the plurality of lasers, wherein the correctiveaction section or the in-situ monitoring system further includes machineinstructions that selects one or more of the build layer defectcorrection action processing sequences in the corrective action librarybased on correlation between a detectable build layer defect pattern orpatterns and an associated build layer defect correction actionprocessing sequences stored in the corrective action library, whereineach of the build layer defect correction action processing sequencesinclude predetermined corrective response actions associated with eachof the defect library entries including an overprint and under printcorrective response action, wherein the plurality of build layer defectcorrection action processing sequences includes machine instructionsequences for controlling at least one of the plurality of lasers toablate some or all of a detected said build layer defects and machineinstruction sequences for controlling the AM printer to fill in oradjust a geometry or section of a subsequently applied build layeradjacent to respective detected defects; a defect library and correctiveaction library input section that provides an operator of the in-situmeasurement and corrective action system a user interface to acceptoperator inputs of new said plurality of build layer defect correctiveaction processing sequences and new said plurality of detectable buildlayer defect patterns; and an in-situ monitoring system section thatreceives inputs from the feature recognition system and interacts orcontrols the defect exploration system, the defect identificationsystem, and the corrective action section as well as the AM system; andat least one controller system that includes at least one processorwhich executes the machine instructions for controlling various elementsincluding the AM system, the plurality of lasers, the measuring system,the in-situ monitoring and corrective response action system, and theorienting system.
 2. The AM system of claim 1, wherein a different laseris used to execute ablative removal of the one or more defects from alaser that is used to perform AM layer build operations.
 3. The AMsystem of claim 1, wherein a first laser is used for melting andconsolidating additive manufacturing material for a respective one ofthe AM build layers and a second laser is utilized for a dual purposecomprising metrology to measure surface roughness, dimensional accuracy,material properties of each AM build layer and, based on evaluatedmeasurements, to execute one or more of the corrective actionscomprising laser ablation to produce a desired surface finish anddimensional accuracy of each said AM build layer.
 4. A method ofoperating an additive manufacturing (AM) system including an in-situmeasurement and corrective action system comprising: providing anadditive manufacturing (AM) system including an in-situ measurement andcorrective action system comprising: an AM system that produces aplurality of AM build layers based on an input AM build file; aplurality of lasers that are operable to selectively orient on andablate material from one or more of the AM build layers and measure theplurality of AM build layers during and after the have been produced bythe AM system; an orienting system for the plurality of lasers; asensing system that includes a sensor or imager system that selectivelyorients towards and generates sensor outputs or sensor data capturese.g., image captures of each AM build layer during or after printing,the sensor outputs or sensor data captures include electromagnetic(e.g., optical, x-rays, etc) and/or thermal images, the sensing systemfurther can include one or more of a group comprising a scanningelectron microscope (SEM), a transmission electron microscope (TEM),thermal profile, and distortion/dimensional profile sensing systems; ameasuring system that receives inputs from at least one of the pluralityof lasers and measures the AM build layer during and after the AM systemprints or produced the AM build layers; a data storage or hard drivestoring a plurality of in-situ monitoring and corrective action systemmachine instructions to operate the system comprising: a defectexploration system that operates the sensing system to generate thesensor outputs or sensor data capture of said AM build layers; a defectidentification system that classifies or identifies one or more defectsin the AM build layers that correlate elements of the sensor outputs orsensor data with stored defect data, the defect identification systemaccesses a defect library including a plurality of detectable buildlayer defect patterns including comparison of the sensor system anddefect exploration system outputs with entries in the defect libraryfiles by a feature or pattern recognition system to identify arespective one of the one or more defects, wherein the defect libraryincludes pixel patterns associated with one or more defects which arecompared by the feature recognition system, wherein the defectidentification system comprises a feature or pattern recognition systemwhich receives outputs of the sensing system including images of thebuild layers from a build object produced from the AM system, thefeature or pattern recognition system comprises a neural network and/orother machine learning system; a corrective action section that includesa corrective action library that includes a plurality of build layerdefect corrective action processing sequences that control the AM systemor at least one of the plurality of lasers, wherein the correctiveaction section or the in-situ monitoring system further includes machineinstructions that selects one or more of the build layer defectcorrection action processing sequences in the corrective action librarybased on correlation between a detectable build layer defect pattern orpatterns and an associated build layer defect correction actionprocessing sequences stored in the corrective action library, whereineach of the build layer defect correction action processing sequencesinclude predetermined corrective response actions associated with eachof the defect library entries including an overprint and under printcorrective response action, wherein the plurality of build layer defectcorrection action processing sequences includes machine instructionsequences for controlling at least one of the plurality of lasers toablate some or all of a detected said build layer defects and machineinstruction sequences for controlling the AM printer to fill in oradjust a geometry or section of a subsequently applied build layeradjacent to respective detected defects; a defect library and correctiveaction library input section that provides an operator of the in-situmeasurement and corrective action system a user interface to acceptoperator inputs of new said plurality of build layer defect correctiveaction processing sequences and new said plurality of detectable buildlayer defect patterns; and an in-situ monitoring system section thatreceives inputs from the feature recognition system and interacts orcontrols the defect exploration system, the defect identificationsystem, and the corrective action section as well as the AM system; andat least one controller system that includes at least one processorwhich executes the machine instructions for controlling various elementsincluding the AM system, the plurality of lasers, the measuring system,the in-situ monitoring and corrective response action system, and theorienting system; operating the AM system to generate an AM build layeron a build platform or section; identifying said one or more saiddefects using the in-situ measurement correction action sections, themeasurement system, the sensor system, the in-situ monitoring section,the defect exploration system, the defect identification system, andcorrective response action system, and the controller system executingthe machine instructions to identify the one or more defects in thebuild layer after some or all of the build layer produced; selecting andexecuting one of the corrective action using the in-situ monitoringsection, the defect exploration section, the defect identificationsection, and corrective response action section, that includes one ormore said build layer defect correction actions including one or morelayer adjustment actions or one or more layer section ablative actions,wherein the one or more layer adjustment action comprises controllingthe AM printer, to adjust the AM system to build the subsequentlyapplied or next AM product layer to adjust a shape or geometry of thesubsequently applied or next AM build layer in response to the detectedone or more defects in a previously applied or built layer comprisingreducing width or adding width at or in proximity to the detecteddefect, wherein the one or more layer section ablative actions comprisesselecting an ablative or material removal operation sequence storedwithin the corrective action library, wherein the ablative or materialremoval operation includes operating at least one of the plurality oflasers and orienting system to remove some or all of the identifieddefect while operating another laser of said plurality of lasers tomonitor ablation or removal of the identified defect a predeterminedtime period and at a predetermined power defined by the an ablative ormaterial removal operation sequence until the in-situ monitoring systemdetermines the defect, including a structural irregularity, is removedor partially removed from the AM build layer.
 5. The method of claim 4,wherein
 2. wherein a different laser is used to execute ablative removalof the one or more defects from a laser that is used to perform AM layerbuild operations.
 6. The method of claim 4, wherein a first laser isused for melting and consolidating additive manufacturing material for arespective one of the AM build layers and a second laser is utilized fora dual purpose comprising metrology to measure surface roughness,dimensional accuracy, material properties of each AM build layer and,based on evaluated measurements, to execute one or more of thecorrective actions comprising laser ablation to produce a desiredsurface finish and dimensional accuracy of each said AM build layer.